Electrochemical microsurface texturing with reusable masked patterned tool

A unique and innovative concept of maskless electrochemical micromachining (EMM) method is used to generate the microsurface textures with low cost and short time. Maskless EMM setup consisting of EMM cell, electrode fixtures, electrode connections and constricted vertical cross flow electrolyte guiding scheme has been developed indigenously to carry out the experimental investigations for the generation of micro circular patterns. In this method, one reusable patterned cathode tool has been utilized to fabricate many high quality micro circular patterns economically. The effect of major process parameters like applied voltage, duty ratio, inter electrode gap, flow rate, pulse frequency and machining time on textured characteristics i.e. overcut, depth and surface roughness (Ra) has been investigated. Arrays of 8000 micro circular impressions are generated by maskless electrochemical micromachining. An analysis has been done to find out the best parametric combination on the basis of micrographs and experimental results.